A new approach to cutting temperature prediction considering the diffusion layer in coated tools

A novel approach to the prediction of cutting temperatures within coated tools is presented in this paper. The diffusion layer that results thermal resistance between coating and its substrate is considered. The diffusion layer model was firstly developed. Equations for effective thermal conductivity of the diffusion layer were then derived based on three structural models such as the Maxwell–Eucken 1 model, the series model, and the equivalent layer model. The influences of diffusion layer on cutting temperatures of coated tools were analyzed. Results indicate that the calculated temperature with the new model is more accurate than that of the conventional one compared with measured temperature. The diffusion layer model developed in this work provides a methodology for the design and choice of coated tools in manufacturing industries.